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Sensing and Imaging for Defect Detection

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A special issue of Sensors (ISSN 1424-8220). This special issue belongs to the section "Sensing and Imaging".

Deadline for manuscript submissions: 20 September 2024 | Viewed by 8699

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Special Issue Editors

Prof. Dr. Haitao Wang

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Guest Editor

Department of Test Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China
Interests: NDT&E technology with ultrasonic, electromagnetic; imaging processing technology; high-imaging-resolution technology

Dr. Yongkai Zhu

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Guest Editor

Informationization Department, Nanjing University of Aeronautics and Astronautics, Nanjing, China
Interests: sensor technology; structural health monitoring technology

Dr. Fei Fei

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Guest Editor

Informationization Department, Nanjing University of Aeronautics and Astronautics, Nanjing, China
Interests: sensor technology; robotics
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Special Issue Information

Dear Colleagues,

With the progress made in science and technology, the quality of people's material and cultural lives has improved, meaning that the requirements for product quality and nondestructive testing technology have further increased. Nondestructive testing technology usually includes five conventional testing technologies, namely eddy current, penetration, magnetic particle, ultrasonic, and X-ray, along with their related new technologies. Usually, different materials need to be detected, and the defects that need to be detected are not the same—for example, for metals, defects include non-metallic pipe defects and slag inclusions, the metal not being welded through, porosity, etc.; for the power transmission of porcelain bottles such as ceramic materials, defects include cracks, porosity, etc.

This Special Issue calls for papers aimed at the detection of the most common defects, including surface defects, subsurface defects and so on. Recent advances in sensor technologies form the basis of the development of nondestructive testing technology, data acquirement processing, and image processing technology.

The editors welcome the submission of high-quality research papers not previously published in other journals as well as review articles discussing recent advancements in the development of sensing and imaging techniques for defect detection technology that can be easily used in the NDT&E field.

Prof. Dr. Haitao Wang
Dr. Yongkai Zhu
Dr. Fei Fei
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sensors is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

sensors NDT&E technology
defect detection technology
imaging technology
data acquirement and processing
sensing techniques

Published Papers (7 papers)

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Research

19 pages, 7720 KiB

Open AccessArticle

Advancing Ultrasonic Defect Detection in High-Speed Wheels via UT-YOLO

by Qian Zhang, Jianping Peng, Kang Tian, Ai Wang, Jinlong Li and Xiaorong Gao

Sensors 2024, 24(5), 1555; https://doi.org/10.3390/s24051555 - 28 Feb 2024

Viewed by 541

Abstract

In the context of defect detection in high-speed railway train wheels, particularly in ultrasonic-testing B-scan images characterized by their small size and complexity, the need for a robust solution is paramount. The proposed algorithm, UT-YOLO, was meticulously designed to address the specific challenges presented by these images. UT-YOLO enhances its learning capacity, accuracy in detecting small targets, and overall processing speed by adopting optimized convolutional layers, a special layer design, and an attention mechanism. This algorithm exhibits superior performance on high-speed railway wheel UT datasets, indicating its potential. Crucially, UT-YOLO meets real-time processing requirements, positioning it as a practical solution for the dynamic and high-speed environment of railway inspections. In experimental evaluations, UT-YOLO exhibited good performance in best recall, mAP@0.5 and mAP@0.5:0.95 increased by 37%, 36%, and 43%, respectively; and its speed also met the needs of real-time performance. Moreover, an ultrasonic defect detection data set based on real wheels was created, and this research has been applied in actual scenarios and has helped to greatly improve manual detection efficiency. Full article

(This article belongs to the Special Issue Sensing and Imaging for Defect Detection)

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24 pages, 5947 KiB

Open AccessArticle

FR-PatchCore: An Industrial Anomaly Detection Method for Improving Generalization

by Zhiqian Jiang, Yu Zhang, Yong Wang, Jinlong Li and Xiaorong Gao

Sensors 2024, 24(5), 1368; https://doi.org/10.3390/s24051368 - 20 Feb 2024

Viewed by 890

Abstract

In recent years, a multitude of self-supervised anomaly detection algorithms have been proposed. Among them, PatchCore has emerged as one of the state-of-the-art methods on the widely used MVTec AD benchmark due to its efficient detection capabilities and cost-saving advantages in terms of labeled data. However, we have identified that the PatchCore similarity principal approach faces significant limitations in accurately locating anomalies when there are positional relationships between similar samples, such as rotation, flipping, or misaligned pixels. In real-world industrial scenarios, it is common for samples of the same class to be found in different positions. To address this challenge comprehensively, we introduce Feature-Level Registration PatchCore (FR-PatchCore), which serves as an extension of the PatchCore method. FR-PatchCore constructs a feature matrix that is extracted into the memory bank and continually updated using the optimal negative cosine similarity loss. Extensive evaluations conducted on the MVTec AD benchmark demonstrate that FR-PatchCore achieves an impressive image-level anomaly detection AUROC score of up to 98.81%. Additionally, we propose a novel method for computing the mask threshold that enables the model to scientifically determine the optimal threshold and accurately partition anomalous masks. Our results highlight not only the high generalizability but also substantial potential for industrial anomaly detection offered by FR-PatchCore. Full article

(This article belongs to the Special Issue Sensing and Imaging for Defect Detection)

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24 pages, 15581 KiB

Open AccessArticle

Anomaly Detection Based on a 3D Convolutional Neural Network Combining Convolutional Block Attention Module Using Merged Frames

by In-Chang Hwang and Hyun-Soo Kang

Sensors 2023, 23(23), 9616; https://doi.org/10.3390/s23239616 - 04 Dec 2023

Viewed by 1473

Abstract

With the recent rise in violent crime, the real-time situation analysis capabilities of the prevalent closed-circuit television have been employed for the deterrence and resolution of criminal activities. Anomaly detection can identify abnormal instances such as violence within the patterns of a specified dataset; however, it faces challenges in that the dataset for abnormal situations is smaller than that for normal situations. Herein, using datasets such as UBI-Fights, RWF-2000, and UCSD Ped1 and Ped2, anomaly detection was approached as a binary classification problem. Frames extracted from each video with annotation were reconstructed into a limited number of images of

3 \times 3

4 \times 3

4 \times 4

5 \times 3

sizes using the method proposed in this paper, forming an input data structure similar to a light field and patch of vision transformer. The model was constructed by applying a convolutional block attention module that included channel and spatial attention modules to a residual neural network with depths of 10, 18, 34, and 50 in the form of a three-dimensional convolution. The proposed model performed better than existing models in detecting abnormal behavior such as violent acts in videos. For instance, with the undersampled UBI-Fights dataset, our network achieved an accuracy of 0.9933, a loss value of 0.0010, an area under the curve of 0.9973, and an equal error rate of 0.0027. These results may contribute significantly to solve real-world issues such as the detection of violent behavior in artificial intelligence systems using computer vision and real-time video monitoring. Full article

(This article belongs to the Special Issue Sensing and Imaging for Defect Detection)

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23 pages, 21780 KiB

Open AccessArticle

CLensRimVision: A Novel Computer Vision Algorithm for Detecting Rim Defects in Contact Lenses

by Pawat Chunhachatrachai and Chyi-Yeu Lin

Sensors 2023, 23(23), 9610; https://doi.org/10.3390/s23239610 - 04 Dec 2023

Viewed by 984

Abstract

Automated optical inspection (AOI) plays a pivotal role in the quality control of contact lenses, safeguarding the safety and integrity of lenses intended for both medical and cosmetic applications. As the role of computer vision in defect detection expands, our study probes its effectiveness relative to traditional methods, particularly concerning subtle and irregular defects on the lens rim. In this research study, we propose a novel algorithm designed for the precise and automated detection of rim defects in contact lenses called “CLensRimVision”. This algorithm integrates a series of procedures, including image preprocessing, circle detection for identifying lens rims, polar coordinate transformation, setting defect criteria and their subsequent detection, and, finally, visualization. The method based on these criteria can be adapted either to thickness-based or area-based approaches, suiting various characteristics of the contact lens. This approach achieves an exemplary performance with a 0.937 AP score. Our results offer a richer understanding of defect detection strategies, guiding manufacturers and researchers towards optimal techniques for ensuring quality in the contact lens domain. Full article

(This article belongs to the Special Issue Sensing and Imaging for Defect Detection)

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24 pages, 9525 KiB

Open AccessArticle

Design and Implementation of a Hardware and Software System for Visual Assessment of Bituminous Coating Quality

by Dmitrii Kamianskii, Alexander Boldyrev, Nikita Vezdenetsky, Irina Vatamaniuk and Marina Bolsunovskaya

Sensors 2023, 23(23), 9325; https://doi.org/10.3390/s23239325 - 22 Nov 2023

Viewed by 590

Abstract

Typically, the quality of the bitumen adhesion in asphalt mixtures is assessed manually by a group of experts who assign subjective ratings to the thickness of the residual bitumen coating on the gravel samples. To automate this process, we propose a hardware and software system for visual assessment of bituminous coating quality, which provides the results both in the form of a discrete estimate compatible with the expert one, and in a more general percentage for a set of samples. The developed methodology ensures static conditions of image capturing, insensitive to external circumstances. This is achieved by using a hardware construction designed to provide capturing the samples at eight different illumination angles. As a result, a generalized image is obtained, in which the effect of highlights and shadows is eliminated. After preprocessing, each gravel sample independently undergoes surface semantic segmentation procedure. Two most relevant approaches of semantic image segmentation were considered: gradient boosting and U-Net architecture. These approaches were compared by both stone surface segmentation accuracy, where they showed the same 77% result and the effectiveness in determining a discrete estimate. Gradient boosting showed an accuracy 2% higher than the U-Net for it and was thereby chosen as the main model when developing the prototype. According to the test results, the evaluation of the algorithm in 75% of cases completely coincided with the expert one, and it had a slight deviation from it in another 22% of cases. The developed solution allows for standardizing the data obtained and contributes to the creation of an interlaboratory digital research database. Full article

(This article belongs to the Special Issue Sensing and Imaging for Defect Detection)

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21 pages, 15269 KiB

Open AccessArticle

Anomaly Detection in Annular Metal Turning Surfaces Based on a Priori Information and a Multi-Scale Self-Referencing Template

by Xinyu Suo, Jie Zhang, Jian Liu, Dezhi Yang and Feitao Zhou

Sensors 2023, 23(15), 6807; https://doi.org/10.3390/s23156807 - 30 Jul 2023

Viewed by 965

Abstract

To solve the problem of anomaly detection in annular metal turning surfaces, this paper develops an anomaly detection algorithm based on a priori information and a multi-scale self-referencing template by combining the imaging characteristics of annular workpieces. First, the annular metal turning surface is unfolded into a rectangular expanded image using bilinear interpolation to facilitate subsequent algorithm development. Second, the grayscale information from the positive samples is used to obtain the a priori information, and a multi-scale self-referencing template method is used to obtain its own multi-scale information. Then, the phase error and large-size anomaly interference problems of the self-referencing method are overcome by combining the a priori information with its own information, and an accurate response to anomalous regions of various sizes is realized. Finally, the segmentation completeness of the anomalous region is improved by utilizing the region growing method. The experimental results show that the proposed method achieves a mean pixel AUROC of 0.977, and the mean M_IOU of segmentation reaches 0.788. In terms of efficiency, this method is also much more efficient than the commonly used anomaly detection algorithms. The proposed method can achieve rapid and accurate detection of defects in annular metal turning surfaces and has good industrial application value. Full article

(This article belongs to the Special Issue Sensing and Imaging for Defect Detection)

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15 pages, 4066 KiB

Open AccessCommunication

Wheel Defect Detection Using a Hybrid Deep Learning Approach

by Khurram Shaikh, Imtiaz Hussain and Bhawani Shankar Chowdhry

Sensors 2023, 23(14), 6248; https://doi.org/10.3390/s23146248 - 08 Jul 2023

Cited by 2 | Viewed by 2319

Abstract

Defective wheels pose a significant challenge in railway transportation, impacting operational performance and safety. Excessive traction and braking forces give rise to deviations from the intended conical tread shape, resulting in amplified vibrations and noise. Moreover, these deviations contribute to the accelerated damage of track components. Detecting wheel defects at an early stage is crucial to ensure safe and comfortable operation, as well as to minimize maintenance costs. However, the presence of various vibrations, such as those induced by the track, traction motors, and other rolling stock subsystems, poses a significant challenge for onboard detection techniques. These vibrations create difficulties in accurately identifying wheel defects in real-time during operational activities, often resulting in false alarms. This research paper aims to address this issue by using a hybrid deep learning-based approach for the accurate detection of various types of wheel defects using accelerometer data. The proposed approach aims to enhance wheel defect detection accuracy while considering onboard techniques’ cost-effectiveness and efficiency. A realistic simulation model of the railway wheelset is developed to generate a comprehensive dataset. To generate vibration data in various scenarios, the model is simulated for 20 s under different conditions, including one non-faulty scenario and six faulty scenarios. The simulations are conducted at different speeds and track conditions to capture a wide range of operating conditions. Within each simulation iteration, a total of 200,000 data points are generated, providing a comprehensive dataset for analysis and evaluation. The generated data are then utilized to train and evaluate a hybrid deep learning model, employing a multi-layer perceptron (MLP) as a feature extractor and multiple machine learning models (support vector machine, random forest, decision tree, and k-nearest neighbors) for performance comparison. The results demonstrate that the MLP-RF (multi-layer perceptron with random forest) model achieved an accuracy of 99%, while the MLP-DT (multi-layer perceptron with decision tree) model achieved an accuracy of 98%. These high accuracy values indicate the effectiveness of the models in accurately classifying and predicting the outcomes. The contributions of this research work include the development of a realistic simulation model, the evaluation of sensor layout effectiveness, and the application of deep learning techniques for improved wheel flat detections. Full article

(This article belongs to the Special Issue Sensing and Imaging for Defect Detection)

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